##### 



th
 
       /s/
Jason Perks
 
 CC:
    
    Shawn Crowe
Director of Fulfillment
RedEnvelope, Inc.




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##### 



Table of Contents
    
    DCS Proposal PM07-66361.0 Scope of Proposal1.1 General Overview1.2 Clarifications2.0 SKU Analysis2.1 Analysis Overview2.2 SKU Group Table2.3 SKU Group Descriptions2.4 Pick Module Design2.4.1 Existing Picking Area2.4.2 New Lower Picking Area2.4.3 New Upper Picking Area2.4.4 New System Storage Totals3.0 Description of Operation3.1 General Overview3.2 Existing Picking Area3.2.1 General Area Description3.2.2 Conveyor Operation3.3 New Picking Area3.3.1 General Area Description3.3.2 Conveyor Operation: Drawing MCL 1003 & 10043.4 Personalization Area3.4.1 General Area Description3.4.2 Conveyor Operation: Drawing MCL 10053.5 Jewelry Packing3.5.1 General Area Description3.6 Packing Sorter3.6.1 General Area Description: Drawing MCL 10063.7 Packing Area3.7.1 General Area Description3.8 Shipping Area3.8.1 General Area Description3.8.2 Conveyor Operation3.9 Order Routing4.0 Specifications and Engineering Calculations4.1 Loads to be Handled4.1.1 Load Sizes4.2 Throughput Calculations4.3 New Picking Sorter Throughput Design4.4 New Picking Aisle Throughput Design4.5 Barcode Specifications4.5.1 Shipping Carton4.5.2 Order Tote
 1




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##### 



Table of Contents
    
    DCS Proposal PM07-66364.5.3 Replenishment Carton4.5.4 Barcode Orientation5.0 Mechanical Equipment5.1 General System Equipment5.2 Sortation Conveyor5.3 Conveyor Schedule5.4 Mechanical Equipment Literature6.0 Conveyor Control System6.1 General Scope6.2 General Electrical Installation Details6.3 Electrical Equipment listing as a complete system per design6.4 DCSware Conveyor Control Software6.4.1 Material Flow Applications6.4.2 Messaging6.4.3 Testing6.4.4 Training7.0 DCSware HMI Software Specifications7.1 General Pages7.1.1 Overview and Detail View Pages7.1.2 Overview Main Page7.2 DCSware HMI System Hardware7.3 Optional Software Modules7.3.1 Shift Time Module7.3.2 Data Logging Module7.3.3 Reporting Module8.0 Items to Provide8.1 DCS to Provide8.2 RedEnvelope to Provide (or Others)9.0 Basis of Offering9.1 Investment Outline9.1.1 Order Fulfillment System Base Investment Offering9.1.2 Optional Order Fulfillment System Investment Offerings9.1.3 Terms & Conditions9.2 Preliminary Project ScheduleAppendix A: Standard Terms & ConditionsAppendix B: DCS Insurance CertificateAppendix C: Engineering Drawings
 2




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##### 



1.0 Scope of Proposal
 General Overview
     
    
    SKU Analysis
    
    PLC & WCS Upgrade
    
    Mezzanines & Support Structures
    
    Existing Picking Area Modifications to handle Cartons
    
    Packing Area re-arrange to improve Ergonomics
    
    Addition of Jewelry Packing Area
    
    Personalization Area Re-arrange
    
    New Picking Area to handle the bulk of the Picking Operations and all Carton
Replenishment Diverting
    
    Shipping Area Upgrades
    3




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
    
    Ermanco (Carton Sortation, Accumulation and Transportation Conveyor)
    
    DCS Fabrication/Transnorm (Belt Curves, Platforms, Structural Steelwork and Conveyor
Specials)
    
    Allen-Bradley (Controls Devices)
    
    DataLogic (Scanning Equipment)
    
    Dell (Computer Hardware)
  4




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##### 



Clarifications
 1)
    
    This proposal is based upon the following SKU data documents provided by RedEnvelope:
 o
    
    ProdData.mdbo
    
    2007 Daily Headcount Q3v4.xlso
    
    Carton Sizes.xlso
    
    Replen_task_from_resv_summary.xlso
    
    Replen_task_from_resv_with_task_desc.xlso
    
    Case Dim
 2)
    
    This proposal is based on DCS providing a complete turn-key system as outlined.3)
    
    All powered conveyors will feature drip pans under the motors. Bottom covers will be
provided for all conveyor located between the heights of 60 and 96 TOR.4)
    
    All powered conveyor will be provided with ABEC Precision bearing rollers for noise
control.5)
    
    Skewed roller sections will be used strategically throughout the system to improve
carton orientation.6)
    
    Each of the Sortation lanes on the New Picking Sorter is designed to have a powered
spur and curve off of the divert. This provides positive movement of product off of the
sorter for positive divert confirmation and to prevent jamming.7)
    
    Upon the completion of the PLC and Middleware upgrade, the system functionality and
performance will remain unchanged from its current operations. Any improvements in system
performance will be made as the system upgrades are implemented. This is done so that the
initial downtime of making the PLC and Middleware change is minimized by not requiring the
debug of additional functionality.8)
    
    No SKU storage mediums (carton flow, shelving, etc.) or installation/un-installation
of those mediums has been included in this proposal. By others.9)
    
    The barcode scanning equipment in the base layout includes single line scanners
set-up to read barcodes in the ladder format. If the barcodes cannot be placed in the
specified position, the scope of investment may change. See Section 4.5.4 in this
proposal.10)
    
    Any required 120V outlets & power to secondary equipment (personalization machines,
packing stations, etc.) are not included in the scope of this proposal. By others.
 5




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11)
    
    RedEnvelope is to furnish and maintain VPN access to the system panels for DCS to
provide remote system support.12)
    
    Equipment will be shipped Collect, F.O.B. ship point. All pre-pay & add shipments
will have 10% added for DCS bookkeeping.13)
    
    Ethernet connections to RedEnvelopes network are not included. Connections between
PLC processors and the other DCS field devices are included. RedEnvelope is to provide
Ethernet connections to network and panels as required for interface with the WMS system.14)
    
    To be properly and consistently conveyed, a carton should be longer than it is wide.
If a carton is square or the length and width dimensions are close to the same, the
orientation of the carton will be difficult to maintain. With respect to the design of
the system, the longest box dimension will be considered the length. The next biggest
dimension will be the width and the smallest the height.15)
    
    The operator interface screens, software and necessary scanning equipment at the Pack
Area and hospital lines are not included in the scope of this proposal. By others.16)
    
    Mechanical and Electrical installation will be with highly skilled non-union labor to
be performed during normal weekday working hours with the required weekend tie-ins.17)
    
    RedEnvelope to provide DCS with a copy of SQL Server no later than April
15th.18)
    
    RedEnvelope to provide servers for DCSs WCS software.19)
    
    RedEnvelope to provide a testing environment to facilitate the testing of DCSs WCS
software while the existing system is in operation without interrupting operations.
 6




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##### 



2.0 SKU Analysis
 Analysis Overview
  
    
    Volume picked each month
    
    Number of picks each month
    
    Number of times on a pick sheet each month
    
    SKU Volume
    
    SKU Length, width & height
   
    
    ProdData.mdb  SKU data for the months of October, November & December of 2006
including SKU size, description, pick quantities, etc.
    
    2007 Daily Headcount Q3v4.xls  Labor estimations for the months of October, November &
December of 2006
    
    Carton Sizes.xls  Sizes of all shipping cartons
    
    Replen_task_from_resv_summary.xls  Number of replenishments made each day for 2006
    
    Replen_task_from_resv_with_task_desc.xls  Number of each type of replenishment
(pallet, case, etc.), each day for 2006
    
    Case Dim  Master Qty.xls  Volume of each master case for a SKU and number of SKU
eaches in that case
 7




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##### 



SKU Group Table
 8




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##### 



SKU Group Descriptions
 Group 1
    Group 2
    Group 3
    9




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##### 



Group 4
    Group 5
    Group 6
    Group 7
  10




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##### 



Group 8
    Group 9
     11




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Pick Module Design
 Existing Picking Area
 
   
    
    Adding a DC Powered Roller at each bi-directional UBT divert in each direction; this
roller will enable the smaller cartons to move across the gap in between the UBTs.
    
    Adding Speed-up Spools prior to the UBTs; this will create more gap between the
smaller cartons and allow the braking system to create the proper gap.
    
    Skewing rollers; this will keep all the cartons edge referenced and in line to avoid
turning cartons and side by side cartons.
 12




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New Lower Picking Area
 
  13




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##### 



New Upper Picking Area
 
  New System Storage Totals
 CartonPallet Flow
    
    Flow
    
    ShelvingExisting Picking
    
    
    46
    
    
    
    244
    
    
    
    125New Lower Picking
    
    
    0
    
    
    
    742
    
    
    
    0New Upper Picking
    
    
    0
    
    
    
    792
    
    
    
    358Total Storage Required
    
    
    46
    
    
    
    1778
    
    
    
    483Available Storage
    
    
    54
    
    
    
    2320
    
    
    
    688Available for SKUs not in Data
    
    
    8
    
    
    
    542
    
    
    
    205Approx. SKUs not in Data (462
SKUs of 1,800)
    
    
    0
    
    
    
    257
    
    
    
    205Remaining Storage for Growth
    
    
    8
    
    
    
    285
    
    
    
    0
 
 *
    
    Note: Storage capacities for the carton flow and shelving are based on each SKU requiring an
18 square picking face. The majority of SKUs will not require this large of a picking face,
allowing for additional picking faces to be created in these storage mediums. 14




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3.0 Description of Operation
 General Overview
   Existing Picking Area
 General Area Description
 Layout
  Picking
   15




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Replenishment
  Storage
  Trash Line
  Conveyor Operation
 Layout
  16




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Picking
      New Picking Area
 General Area Description
 Layout
  17




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##### 



Picking
    Storage
  18




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##### 



Replenishment
  Trash Line
  Conveyor Operation: Drawing MCL 1003 & 1004
 Layout
  Picking
    19




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##### 



20




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Replenishment
   Personalization Area
 General Area Description
  Conveyor Operation: Drawing MCL 1005
   21




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Jewelry Packing
 General Area Description
  Packing Sorter
 General Area Description: Drawing MCL 1006
   Packing Area
 General Area Description
  22




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##### 



Shipping Area
 General Area Description
  Conveyor Operation
     23




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##### 



Order Routing
  1.
    
    Picking of VAS items
 o
    
    (5) Pick Zones in existing picking area
 2.
    
    VAS Process diverts
 o
    
    (4) VAS processing areas
 3.
    
    Non-VAS item picking
 o
    
    (1) Pick Zone in the existing picking areao
    
    (14) Pick Zones in the new picking area
 4.
    
    Jewelry Item Picking
 o
    
    (2) Pick Zones in the new picking area
 5.
    
    Jewelry Gift box
 o
    
    (2) Pick Zones in the new picking area
 6.
    
    Gift Wrap
 o
    
    (1) Wrapping Zone in the existing packing area
 7.
    
    Jewelry only Packing
 o
    
    (1) Packing Zone in the existing packing area
 8.
    
    Gift Box
 o
    
    (1) Pick Zone in the existing packing area
 9.
    
    Non-Gift Box Packing (orders with Jewelry and another item)
 o
    
    (1) Packing Zone in the existing packing area
 24




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4.0 Specifications and Engineering Calculations
 Loads to be Handled
   Load Sizes
  RedEnvelope Carton & Tote SizesOutside DimensionsCarton #
    
    % Usage
    
    Length
    
    Width
    
    Height10A
    
    
    24.2
    %
    
    
    10
    
    
    
    8
    
    
    
    412A
    
    
    3.0
    %
    
    
    12
    
    
    
    10
    
    
    
    412B
    
    
    13.1
    %
    
    
    12
    
    
    
    10
    
    
    
    812C
    
    
    3.4
    %
    
    
    12
    
    
    
    12
    
    
    
    1214A
    
    
    10.5
    %
    
    
    14
    
    
    
    14
    
    
    
    815A
    
    
    3.6
    %
    
    
    15
    
    
    
    15
    
    
    
    1616A
    
    
    14.6
    %
    
    
    16
    
    
    
    16
    
    
    
    1024A
    
    
    8.7
    %
    
    
    24
    
    
    
    12
    
    
    
    1224B
    
    
    9.8
    %
    
    
    24
    
    
    
    15
    
    
    
    2228A
    
    
    1.0
    %
    
    
    28
    
    
    
    18
    
    
    
    829A
    
    
    8.1
    %
    
    
    29
    
    
    
    11
    
    
    
    15Tote
    
    
    N/A
    
    
    
    25
    
    
    
    19.5
    
    
    
    10
 
    
    Average Carton Length based on percentage of usage of each length of carton is
14.2. We will use 15 for throughput calculations.
 o
    
    Note: If the 10A carton is made to be 12 long, the average carton
length is still less than 15.
 25




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Throughput Calculations
 Overall Throughput
    37 CPM
 New Picking Sorter
       100 CPM
 New Picking Aisle
      18 CPM
 26




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##### 



Existing Picking Area
      14.5 CPM
  Existing Shipping Sorter
     38.5 CPM
  27




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New Picking Sorter Throughput Design
 100 CPM
 
 28




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New Picking Aisle Throughput Design
 18 CPM
 
 29




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Barcode Specifications
   Shipping Carton
 Existing Picking, VAS, Packing Sorter, New Picking Induction, New Picking Aisles, Shipping
Sorter & Jewelry Packing
    
    Symbology:
    
    UCC 128 subset A switching to subset C after 1Z
    
    Characters:
    
    18
    
    Min Narrow element:
    
    0.015
    
    Pattern Height:
    
    31.0
    
    Quiet Space:
    
    30.25
 Order Tote
 New Picking Induction & New Picking Jewelry Aisle
    
    Symbology:
    
    UCC 128 subset B
    
    Characters:
    
    10 (1 letter, 9 digits)
    
    Min Narrow element:
    
    0.015
    
    Pattern Height:
    
    31.0
    
    Quiet Space:
    
    30.25
 Replenishment Carton
 New Picking Induction, Existing Picking Area
    
    Symbology:
    
    UCC 128 subset B
    
    Characters:
    
    10 (1 letter, 9 digits)
    
    Min Narrow element:
    
    0.015
    
    Pattern Height:
    
    30.75
    
    Quiet Space:
    
    30.25
 30




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Barcode Orientation
 
 31




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##### 



5.0
    
    Mechanical Equipment5.1
    
    General System Equipment
  
    
    Zero Pressure Accumulation Conveyors
 O
    
    Ermanco NBA 23  22 B.F.
 §
    
    Rollers: 1.9 dia. x 16 ga. rollers  7/16 Hex steel axle, spring
retained on 3 centers
 
    
    ABEC Precision Bearings
 §
    
    Frame: CRUZ channel 7
1/2'' x 1 5/8'' x 12 gauge formed channel§
    
    Drive Belt: 2 wide w/welded splice§
    
    Zones: 3 zones with CRUZcontrol photo eyes
 O
    
    Ermanco XP43CZ Xenopressure  22 B.F.
 §
    
    Rollers: 1.9 dia. x 16 ga. rollers  7/16 Hex steel axle, spring
retained on 3 centers
 
    
    ABEC Precision Bearings
 §
    
    Frame: CRUZ channel 7
1/2''
x 1 5/8'' x 12 gauge formed channel§
    
    Drive Shaft: 1 dia. TG&P cold rolled steel§
    
    Zones: 3 non-contact zones with CRUZcontrol photo eyes
 
    
    Transportation Conveyors
 O
    
    Ermanco XenoROL XR40  22 B.F.
 §
    
    Rollers: 1.9 dia x 16 ga. rollers  7/16 Hex steel axle, spring
retained on 3 centers
 
    
    ABEC Precision Bearings
 §
    
    Frame: CRUZ channel 7
1/2''
x 1 5/8'' x 12 gauge formed channel§
    
    Drive Shaft: 1 dia. TG&P cold rolled steel
 
    
    Incline/Decline Belt Conveyors
 O
    
    Ermanco CRUZbelt 15 deg Inclines/Declines  22 B.F.
 §
    
    Rollers: 1.9 dia. x 16 ga. rollers  7/16 Hex steel axle, spring
retained on 6 centers
 
    
    ABEC Precision Bearings
 §
    
    End Pulleys: 2-1/2 dia. for smooth transition of small products§
    
    Belting: Monofilament Belt§
    
    Frame: CRUZ channel 7
1/2''
x 1 5/8'' x 12 gauge formed channel§
    
    Take-up: Self aligning
 32




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
    
    Live Roller Curves
 O
    
    Ermanco RLC 25  22 B.F.
 §
    
    Rollers: 1.9 dia. x 16 ga. rollers  7/16 Hex steel axle, spring
retained on 3 centers with true taper
 
    
    ABEC Precision Bearings
 §
    
    Frame: CRUZ channel 7
1/2''
x 1 5/8'' x 12 gauge formed channel§
    
    Drive Belt: Spliceable with greater tensile strength than standard
v-belts
 
    
    Lineshaft Curves
 O
    
    Ermanco XR40 Curves  22 B.F.
 §
    
    Frame: CRUZ channel 7
1/2''
x 1 5/8'' x 12 gauge formed channel§
    
    Rollers: Rollers: 1.9 dia. x 16 ga. rollers  7/16 Hex steel axle,
spring retained on 3 centers§
    
    Drive Shaft: 1 dia. TG&P cold rolled steel
 
    
    Belt Curve
 O
    
    Transnorm Systems TS1500/140 Power Belt Curve
 §
    
    38Inside Radius§
    
    90° Power Curve§
    
    Belt Width: 21, 22 between guards§
    
    Drive: 1 HP SEW Eurodrive motor and reducer 230/460/60/3§
    
    Belt: Black, High Friction, Clipper Laced
 
    
    Trash Conveyor
 O
    
    HK Systems BSE Slider Bed Belt Conveyor
 §
    
    End Drive with 4
1/2 dia. lagged pulley with 1 3/16 Shaft§
    
    End Take-up with 3 1/2 dia. pulley with 1 1/8 square shaft§
    
    7 1/2 deep x 10 ga. formed channel frames§
    
    Center take-up with 3 1/2 dia. pulley
 5.2
    
    Sortation Conveyor
 
    
    Brake/Spacer Belt Conveyor
 O
    
    Ermanco CRUZbelt 22 B.F.
 §
    
    Slider Bed: Formed pan§
    
    End Pulleys: 2-1/2 dia. for smooth transition of small products§
    
    Belting: Monofilament Belt§
    
    Frame: CRUZ channel 7
1/2''
x 1 5/8'' x 12 gauge formed channel
 33




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
    
    High Speed Sorter
 O
    
    Ermanco NBS 30 Wave Sorter
 §
    
    Frame: 5 3/4 x 10 ga§
    
    End Pulley: 6-5/8 deep x 10 ga. frame, 4 dia. flat face§
    
    End drive: 20-7/8 deep x 7 ga. frame, 8 dia. pulley flat face§
    
    Wave Diverter: 9-1/4 deep x 10 ga. frame, 6 rows of wheels§
    
    Belts: PVC 1.25 w x .203 thick, 85 Durometer§
    
    Belt guides: Low friction UHMW
 
    
    4-Directional Sorter Conveyor (New Picking Area)
 O
    
    Ermanco ERS
 §
    
    1/2 HP VFD Reversible Drive§
    
    5-strands on 4 centers§
    
    (2) receiving UBTs with Reversing DC Powered Rollers
 34




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5.3
    
    Conveyor Schedule
 35




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##### 



5.4
    
    Mechanical Equipment Literature
 36




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##### 



6.0
    
    Conveyor Control System6.1
    
    General Scope
   
    
    480V/3ph/60Hz power to the line-side of disconnects in the individual motor control
panels. There could be one to three individual control panels for the entire system,
requiring a total of 400 Amps with a maximum Short Circuit Current Rating of 5,000 Amps
per control panel. Control power will be transformed to 120V/1ph/60Hz and 24Vdc to
provide power for logic relays, motor starters, photoelectric, and limit switches and
other conveyor control equipment. This control power source is not conditioned, nor is it
intended to survive the loss of plant utility power. When plant utility power fails, all
electrical devices associated with this source will fail to the OFF state. When power is
restored, a re-initialization sequence is required to return the system equipment to an
operational mode.
 6.2
    
    General Electrical Installation Details
          37




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6.3
    
    Electrical Equipment listing as a complete system per design
  O
    
    - (-) Control Enclosures, Nema 12, floor mount with:
                      38




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##### 



6.4
    
    DCSware Conveyor Control Software
 6.4.1
    
    Material Flow Applications
  A.

    System Flow Control
  
 6.4.1.A.1 Sorter Manager
  Field
    
    Value
    
    Type
    
    CommentsID
    
    Identifies Sorter
    
    VARCHAR(2)
    
    Unique ID for SorterDescription
    
    Sorter Name
    
    VARCHAR(20)
    
    Sorter NameShortDescription
    
    Short Description
    
    VARCHAR2(6)
    
    Used to link system messages with the
appropriate sorter. Found in the
application logs.OPCTopic
    
    Identify which PLC to
communicate with
    
    VARCHAR(10)
    
    Must be setup in RSLinx firstGiftBoxLane
    
    Gift box lane
    
    INT
    
    Designate the lane for cartons with
Gift Box = YNoReadLane
    
    Identify the no read lane
    
    INT
    
    When a barcode is unreadUnderWeightLane
    
    Under Weight Lane
    
    INT
    
    Assigns this sorters under weight lane;
Ignore if no scale present
 39




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Field
    
    Value
    
    Type
    
    CommentsOverWeightLane
    
    Over Weight Lane
    
    INT
    
    Assigns this sorters over weight lane;
Ignore if no scale presentCartonNotFoundLane
    
    Carton Not Found Lane
    
    INT
    
    If the barcode is not found in the
database, the package will be sent to
this lane.SorterRunningTag
    
    Sorter Running Tag
    
    VARCHAR(20)
    
    Internal Status FlagHBTag
    
    Heart Beat Tag
    
    VARCHAR(20)
    
    Establishes communication with the PLCBarcodeTag
    
    Barcode Tag
    
    VARCHAR(20)
    
    Scanned BarcodeIDTag
    
    ID Tag
    
    VARCHAR(20)
    
    Internal Tracking TagDiverTag
    
    Divert Tag
    
    VARCHAR(20)
    
    Internal Tracking TagConfirmTag
    
    Confirm Tag
    
    VARCHAR(20)
    
    Internal Tracking TagFailTag
    
    Fail Tag
    
    VARCHAR(20)
    
    Internal Tracking TagPauseInductionTag
    
    Pause Induction Tag
    
    VARCHAR(20)
    
    Instructs the sorter to stop inductionScale
    
    Scale Present
    
    VARCHAR(1)
    
    Barcode Tag will include a weight stringIPAddress
    
    IP Address
    
    VARCHAR(15)
    
    IP AddressNumberOfDiverts
    
    Number of Diverts
    
    INT
    
    Number of DivertsTypeOfSorter
    
    Type of Sorter
    
    VARCHAR(1)
    
    Type of Sorter
 
  6.4.1.A.2 Carton History
  40




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##### 



6.4.1.A.3 Carrier Management
  6.4.1.A.4 Completed Cartons (Shipped Cartons)
  B.
    
    Link Administrator
  6.4.1.B.1 Carton Weight Tolerance
  6.4.1.B.2 Configuration Parameters
 ID
    
    Description
    
    Default Value
    
    CommentsID
    
    Identifies Sorter
    
    VARCHAR(2)
    
    Unique ID for Sorter1000
    
    Do Passwords Expire?
    
    NO1010
    
    Days before a password expires
    
    
    901100
    
    Purge Old Carton Data
    
    YES
    
    Disabled only during debug1110
    
    Days to keep Old Carton Data
    
    
    90
    
    
    Not to exceed 120 days1200
    
    Purge Log Files
    
    YES
    
    Disabled only during debug1210
    
    Days to Keep Log Files
    
    
    120
    
    
    Not to exceed 120 days1400
    
    Wave File Download Path
    
    C:\\DCS\\Downloads\\1410
    
    Wave Data Flag File Name
    
    WAVE.flg
    
    Signals that the wave has
been completely
transferred and is ready
to be processed.1420
    
    Dump Directory for Processed
Wave Files
    
    C:\\DCS\\Downloads\\
Processed\\
    
    Once a Wave download has
been processed, the file
is renamed and
transferred to this
directory.1430
    
    Purge Processed Wave Files
    
    YES
    
    Disabled only during debug1440
    
    Days to keep processed wave files
    
    
    90
    
    
    Not to exceed 120 days1500
    
    CommLink  Server IP Address
    
    
    192.168.0.1001502
    
    CommLink  Server Port
    
    
    50021504
    
    LinkAdmin  Socket Port
    
    
    5001
 41




---



##### 



rd
 6.4.1.C.1 Microsoft SQL Server 2000
  6.4.1.C.2 RSLinx
  6.4.1.C.3 Kassel dOPC Runtime
  6.4.1.C.4 SDAC Runtime
  D.

    Training
 6.4.1.D.1 Operator Training
  6.4.1.D.2 Administrator Training
  6.4.1.D.3 Operator Manuals
  42




---



##### 



6.4.1.D.4 Defined Parameters
  6.4.2
    
    Messaging
  A.
    
    DWAVE
  6.4.2.A.1 Format
  Field
    
    Value
    
    Type
    
    CommentsMessage Type
    
    Wave, Pick, etc.
    
    VARCHAR2(5)
    
    Identifies the process that generated the
message from WM. WAVE for initial Download.Carton Number
    
    CARTON_HDR.CARTON_NBR
    
    VARCHAR2(20)
    
    Unique ID for Carton.Carton Status
    
    CARTON_HDR. STAT_CODE
    
    NUMBER(2)
    
    The Status of the carton in the outbound
process. For all messages generated during
the wave, the value is 10 (Printed).Location Zones
    
    ALLOC_INVN_DTL.PIKR_NBR where 
ALLOC_INVN_DTL.CARTON_NBR =
CARTON_DTL.CARTON_NBR and 
ALLOC_INVN_DTL.CARTON_SEQ_NBR
= CARTON_DTL.CARTON_SEQ_NBR 
and CARTON_DTL.MISC_INSTR_CODE_1
    
    VARCHAR2(50)
ALLOC_INVN_DTL.PIKR_
NBR is
NUMBER(3)
    
    WM sends the pick zones for any eligible
divert. See 1.1.1
 43




---



##### 



Field
    
    Value
    
    Type
    
    CommentsEstimated Weight
    
    CARTON_HDR.EST_WT
    
    NUMBER(13,4)
    
    Sum total of the unit weight of the SKUs in
the carton plus carton weight.Ship Via
    
    CARTON_HDR.SHIP_VIA
    
    VARCHAR2(4)
    
    Indicates the initial Ship Via for the carton.Tracking Number
    
    CARTON_HDR. TRKG_NBR
    
    VARCHAR2(30)
    
    Indicates the tracking number for the carrier.Tote ID
    
    CARTON_HDR.PLT_ID
    
    VARCHAR2(20)
    
    Indicates the Tote ID to which the carton (or
collate) is tied. This is BLANK on the
initial download.Pickticket Control 
Number
    
    CARTON_HDR.PKT_CTRL_NBR
    
    VARCHAR2(10)
    
    Links the carton with the pick ticket it is
associated with.Wave Number
    
    CARTON_HDR.WAVE_NBR
    
    VARCHAR2(12)
    
    Wave number for the Carton. Based on the RE
operational flow,Special Processing 
Flag 1
    
    Carton_Hdr.Misc_Instr_Code_1
    
    VARCHAR2(2)
    
    A value of GB identifies Carton as
requiring a Gift BoxSpecial Processing 
Flag 2
    
    Carton_Hdr.Misc_Instr_Code_2
    
    VARCHAR2(2)
    
    A value of N indicates Ship Alone cartonSpecial Processing 
Flag 3
    
    Carton_Hdr.Misc_Instr_Code_3
    
    VARCHAR2(2)
    
    A value of PH indicates a Pack and Hold
CartonSpecial Processing 
Flag 4
    
    TBD
    
    VARCHAR2(2)
    
    TBD or future useSpecial Processing 
Flag 5
    
    TBD
    
    VARCHAR2(2)
    
    TBD or future useLast Modified User 
ID
    
    CARTON_HDR.USER_ID
    
    VARCHAR2(15)
    
    Last modified user ID. This is the Wave
program for the initial download.Date Time Stamp
    
    Sysdate
    
    DATE
    
    YYYYMMDDHHMMSS
  B.
    
    DSHIP
   Field
    
    Value
    
    Type
    
    CommentsMessage Type
    
    SHIP
    
    VARCHAR2(5)
    
    Identifies the process that generated
the message from WCSCarton Number
    
    Return of carton nbr
    
    VARCHAR2(20)
    
    Unique ID for Carton.Shipping Lane
    
    Final Shipping Lane
    
    VARCHAR2(2)
    
    WCS sends the final shipping zone to
WM for reference. If this is a
two-byte code, then it may be mapped
to CARTON_HDR. CARTON_DIVRT_CODEActual Weight
    
    Actual Weight for carton
    
    NUMBER(13,4)
    
    Mapped to CARTON_HDR. ACTL_WT
 44




---



##### 



Field
    
    Value
    
    Type
    
    CommentsLast Modified User ID
    
    WCS
    
    VARCHAR2(15)
    
    Mapped to CARTON_HDR. USER_IDDate Time Stamp
    
    Sysdate
    
    DATE
    
    Mapped to CARTON_HDR. MOD_DATE_TIME
 C.
    
    DPICK
  Field
    
    Value
    
    Type
    
    CommentsMessage Type
    
    PICK
    
    VARCHAR2(5)
    
    Identifies the
process that
generated the
message from WM.
PICK for message
generated from RF
Pack Pick Cart
function.Carton Number
    
    CARTON_HDR.CARTON_NBR
    
    VARCHAR2(20)
    
    Unique ID for Carton.Carton Status
    
    CARTON_HDR.
STAT_CODE
    
    NUMBER(2)
    
    The Status of the
carton in the
outbound process.
15 for cartons
with multiple picks
or 20 for
completed cartons.Tote ID
    
    CARTON_HDR.PLT_ID
    
    VARCHAR2(20)
    
    Indicates the Tote
ID to which the
carton (or collate)
is tied. Always
prefixed with a TLocation Zones
    
    ALLOC_INVN_DTL.PIKR_
NBR is
NUMBER(3)
    
    VARCHAR2(50)
    
    WM sends the pick
zone that JUST
COMPLETED picking.
WCS directs the tote
to the next zone as
specified on the
initial download.Last Modified User ID
    
    CARTON_HDR.USER_ID
    
    VARCHAR2(15)
    
    Last modified user
ID. This is the
Wave program for the
initial download.Date Time Stamp
    
    Sysdate
    
    DATE
    
    YYYYMMDDHHMMSS
 D.
    
    DTOTE
  Field
    
    Value
    
    Type
    
    CommentsMessage Type
    
    TOTE
    
    VARCHAR2(5)
    
    Identifies the
process that
generated the
message from WM.
TOTE for message
generated from RF
Make Pick Cart
function.Carton Number
    
    CARTON_HDR.CARTON_NBR
    
    VARCHAR2(20)
    
    Unique ID for Carton.Carton Status
    
    CARTON_HDR. STAT_CODE
    
    NUMBER(2)
    
    The Status of the
carton in the
outbound process.
10 for most
cartons, 15 or
20 for totes out
of Personalization.Tote ID
    
    CARTON_HDR.PLT_ID
    
    VARCHAR2(20)
    
    Indicates the Tote
ID to which the
carton (or collate)
is tied. Always
prefixed with a TLast Modified User ID
    
    CARTON_HDR.USER_ID
    
    VARCHAR2(15)
    
    Last modified user
ID. This is the
Wave program for the
initial download.Date Time Stamp
    
    Sysdate
    
    DATE
    
    YYYYMMDDHHMMSS
 45




---



##### 



§
    
    The Personalization process utilizes different tote types. Only T
type totes, however, are placed on the conveyor system.
 6.4.2.D.1
    
    DTOTE may be updated to contain 2 additional fields. Red Envelope is
still working with Manhattan on this. These 2 fields will be for shipping
(telling DCS if it is ok to ship) and will show up in the TOTE message.
This message will be sent out as soon as the order is picked complete. This
allows plenty of time to get a response from WM before the order gets to the
shipping sorter. The format will be as follows:
 Ship_Flag_Stat
    
    10, 90, 80
    
    Number(2)
    
    Field indicates the status of
manifesting checks:
10 indicates that the checks have not
been performed
90 indicates that the checks have been
passed
80 Indicates that the checks have failedFailed_Manif_check_reason
    
    Null
    
    VARCHAR2(20)
    
    This field is only updated when the
Ship_fllg_Stat goes to 80 and indicates
the reason for failure
   Field
    
    Value
    
    Type
    
    CommentsMessage Type
    
    CNCL
    
    VARCHAR2(5)
    
    Designates Cancelled WaveWave Number
    
    CARTON_HDR.WAVE_NBR
    
    VARCHAR2(12)
    
    Wave Number. WCS
deletes all cartons that
have this wave number.
    46




---



##### 



Field
    
    Value
    
    Type
    
    CommentsMessage Type
    
    SVIA
    
    VARCHAR2(5)
    
    Identifies the
process that
generated the
message from WM.
SVIA message is
generated from UI
Pickticket
Inq/Maintfunction.Pickticket Control Nbr
    
    PKT_HDR.PKT_CTRL_NBR
    
    VARCHAR2(10)
    
    This is the Pick
ticket Control
Number for which
the Ship Via has
been changed.Ship Via
    
    PKT_HDR.SHIP_VIA
    
    VARCHAR2(4)
    
    This is the new
Ship Via that has
been changed
through the UI
option.Last Modified User ID
    
    PKT_HDR.USER_ID
    
    VARCHAR2(15)
    
    Last modified user
ID. This is the
Wave program for
the initial
download.Date Time Stamp
    
    Sysdate
    
    DATE
    
    YYYYMMDDHHMMSS
  
    
    WCS uses the Pick ticket Control Number sent in the above message to cross reference
the carton number to update.
    
    New shipping labels are required for cartons involved with the shipping change prior to
loading on the truck. Since the carton can be in any stage of the process when this
change occurs, all cartons, so changed must be sent to the exceptions lane at the end of
the shipping sorter. At this point, new shipping labels are applied to the carton and the
carton is manifested manually
  Following is a list of possible divert areas and the order in which DCS will process these
diverts. This information will be passed down to DCS via the WAVE FTP download in the
Location Zones field. Each zone will be separated by a comma. The numbers are just a
reference, and can be changed, but the order needs to stay the same. For example, Picking
of VAS items must always have lower numbers than VAS Process diverts, but dont
necessarily have to be numbered 110-150. Below is the list:
 O
    
    Picking of VAS items
 §
    
    (5) Pick Zones in existing picking area (110  150)
 O
    
    VAS Process diverts
 §
    
    (4) VAS processing areas (160  190)
 O
    
    Non-VAS item picking
 §
    
    (1) Picking Zone in the existing picking area (200)§
    
    (14) Picking Zones in the new picking area (210  340)
 O
    
    Jewelry Item Picking
 §
    
    (2) Picking Zones in the new picking area (350, 360)
 O
    
    Jewelry Gift box
 §
    
    (2) Picking Zones in the new picking area (350, 360)
 O
    
    Gift Wrap
 §
    
    (1)Wrapping Zone in the existing packing area (370)
 O
    
    Jewelry only Packing
 §
    
    (1) Picking Zone in the existing packing area (380)
 O
    
    Gift Box
 §
    
    (1) Picking Zone in the existing packing area (390)
 47




---



##### 



Testing
     Training
    48




---



##### 



7.0
    
    DCSware HMI Software Specifications7.1
    
    General Pages
 Material Handling Status
  Standard Conveyor Colors
 O
    
    Off
    
    -GreyO
    
    Running
    
    -GreenO
    
    E-stop
    
    -RedO
    
    Fault
    
    -BlueO
    
    Jammed
    
    -YellowO
    
    Full
    
    -Orange
  Ease of use
  Overview and Detail View Pages
  
    
    System View and Status  A view of the conveyor for that area (entire system in the
case of the Overview screen, or a section of the overall system for a Detail View
screen)
 49




---



##### 




    
    Menu  The menu provides access to various functions:
 
 O
    
    System Views  access to Detail View screensO
    
    Users (not shown on menu above)  this can be added upon request to provide
secure access to certain functions (system shutdown, for example)O
    
    System Start/Stop  displays the system start/stop pop up pageO
    
    Help
 §
    
    Conveyor color scheme  displays the conveyor color pop up page§
    
    About DCSware  displays contact information
 50




---



##### 




    
    Navigation Tabs  located across the bottom of the screen, these tabs provide quick access to the zoomed in detail view screens
    
    Conveyor Color Key  located in the bottom right corner of the screens, this section explains the meaning of the conveyor colors
    
    Date  todays date appears in the upper right hand corner of all main pages
Time  the current time appears in the upper right hand corner of all main pages
 51




---



##### 



Overview Main Page
 
 
    
    This page will display a low detail view of all DCS conveyor
    
    Able to diagnose the status of entire areas at a glance
 52




---



##### 



User Security
   
 Alarms
  
  
 Starting Sections of the System
  Real Time Information
    O
    
    Induction countO
    
    Divert failure countO
    
    No Read countO
    
    No Reads percentage
  O
    
    Divert CountO
    
    Full Count
 53




---



##### 



User Help
  
    
    A page describing the colors and what they mean
    
    A page with DCS Contact information
 7.2
    
    DCSware HMI System HardwarePrimary Setup for Two or less HMI Locations:
 
    
    Dell Desktop with monitor, keyboard, mouse
 o
    
    Touch Screen Optional
 
    
    Enclosure for the computer
    
    Windows Operating System Licensing
    
    Development Software System Licensing
    
    1/2 hour UPS system
 Primary Setup for Three or more HMI Locations:
 
    
    Terminal Services Computer
    
    CAL Licensing equal to the number of HMI Locations
    
    1/2 hour UPS system
    
    One Thin Client with monitor, keyboard, mouse per location
 o
    
    Touch Screen Optional
 
    
    Enclosure for the computer
 7.3
    
    Optional Software Modules
 7.3.1
    
    Shift Time Module
  7.3.2
    
    Data Logging Module
  
    
    An additional computer
    
    Data storage for 1 year
    
    Microsoft SQL processor licensing, allowing unlimited connections by clients local
computers.
    
    1/2 hour UPS system
 54




---



##### 




    
    jam counts and jam lengths
    
    motor fault counts and motor fault lengths
    
    full counts and full lengths
    
    motor on counts and motor on lengths
    
    motor off counts and motor off lengths
    
    E-stop counts and E-stop lengths
    
    sorter induction counts
    
    sorter individual divert counts
    
    sorter no read counts
    
    sorter divert failure counts
    
    sorter divert full counts
  7.3.3
    
    Reporting Module
  
 55




---



##### 



8.0
    
    Items to Provide8.1
    
    DCS to Provide
  1)
    
    Conveyor components, supports, devices, and guarding as specified in this proposal.2)
    
    All PLC level, hardwired and pneumatic controls required for the proper operation of
the conveyor system, as defined in this proposal.3)
    
    Responsibility for implementing the proposed system, including Project Management for
coordinating the design, engineering, scheduling, and installation of the proposed system.4)
    
    A properly supervised, trained, non-union work force for the mechanical installation,
air piping and field wiring of the proposed system.5)
    
    All necessary lift equipment to facilitate the mechanical and electrical installation
of the system as proposed.6)
    
    Compliance with the most recent version of applicable OSHA, CEMA, and ANSI standards,
as written at the time of this proposal. We will also comply with any state and local
codes and requirements, however the cost and schedule impact of compliance with any state
or local codes (such as layout modifications, equipment ratings, permits and the cost of
obtaining them, etc.) are not included in this proposal.7)
    
    Regular clean up of the job site during installation, including trash and packing
material removal to customer-provided dumpsters.8)
    
    Three (3) copies of maintenance manuals with spare parts listings, as-built layout
drawings and electrical schematics at the completion of the project. A preliminary spare
parts listing will be provided prior to system implementation to aid RedEnvelope in
obtaining the appropriate parts to support the system commissioning.
 56




---



##### 



8.2
    
    RedEnvelope to Provide (or Others)
 1)
    
    All fire protection equipment required as a result of the system installation,
including sprinklers, fire door openings, fire doors and alarm signals to the conveyor
control system.2)
    
    Any electrical or mechanical permits as required by state or local authorities.3)
    
    480V/3ph/60Hz power to the line-side of disconnects in the individual motor control
panels. There could be one to three individual control panels for the entire system,
requiring a total of 400 Amps with a maximum Short Circuit Current Rating of 5,000 Amps
per control panel.4)
    
    Additional SKU storage mediums and installation as outlined by DCS in this proposal.5)
    
    A good supply of 100 psi clean, dry air to multiple points around the system as
indicated by DCS.6)
    
    Communication wiring between host computer and the Conveyor Control PLC.7)
    
    A representative sample of product and labels to be used for system design and
testing. Product must be a complete representation of all sizes and weights of products to
be handled, in quantities defined by the Project Manager. Because this product will be
tested several times through the system, some damage of test product should be expected.8)
    
    Responsibility for the proper calculation, collection and payment of any taxes
required as a result of this work.9)
    
    Purchase recommended spare parts prior to system run-off to assist DCS in warranty.10)
    
    Two day turn-around of all Approval Drawings.11)
    
    Manpower to load and unload system during commissioning.12)
    
    Server for DCS Middleware Software and a licensed version of SQL Server.13)
    
    Please see the Standard Terms & Conditions located in Appendix A for further
information.
 57




---



##### 



9.0
    
    Basis of Offering9.1
    
    Investment Outline
 9.1.1
    
    Order Fulfillment System Base Investment Offering
  Total Turn-key Investment for Base System:
    
    
    *9.1.2 Optional Order Fulfillment System Investment OfferingsA. Additional Divert for Existing Shipping SorterTotal Turn-key Investment:
    
    
    *
    AdderB. Upgraded In-Motion Scale for Existing Shipping Sorter
(40 CPM, +/- 0.01 lbs accuracy)Total Turn-key Investment:
    
    
    *
    AdderC. Upgraded In-Motion Scale for Existing Shipping Sorter
(53 CPM, +/- 0.01 lbs accuracy)Total Turn-key Investment:
    
    
    *
    AdderD. Trash Conveyor for Existing PickingTotal Turn-key Investment:
    
    
    *
    AdderE. Replenishment Line for Existing PickingTotal Turn-key Investment:
    
    
    *
    AdderF. Remote HMI Interface Touch ScreenTotal Turn-key Investment:
    
    
    *
    Adder
  58




---



##### 

\

9.1.3
    
    Terms & Conditions
 
    
    
    *
    
    
    Upon Layout Design Acceptance (March 31st):
    
    Net 30 days
    
    
    *

    
    Upon Delivery of Detailed Approval
Drawings (April 13th):
    
    Net 30 days
    
    
    *
    
    
    Upon 1st Shipment of Equipment (May 14th):
    
    Net 30 days
    
    
    *

    
    Upon Completion of Installation (September 14th):
    
    Net 30 days
    
    
    *

    
    Upon Final Acceptance by RedEnvelope
(September 30th):
    
    Net 30 days
 1)
    
    Prices are valid for 30 days.2)
    
    Above prices do not include taxes.3)
    
    Above prices do not include freight.
 Freight: Collect, FOB Shipping Point
   59




---



##### 



9.2
    
    Preliminary Project Schedule
 60




---



##### 



Proposal Notes




---



##### 



DCS Proposal Acceptance RevB  PM07-6636
  
       (DCS LOGO)
    
    Designed Conveyor Systems of Michigan, Inc.
4890 Kendrick St. SE
Grand Rapids, MI 49512
(616) 977-3950 phone(616) 977-5006 fax
Jason. Perks@dcsmich.com
  Page 1 of 2




---



##### 



DCS Proposal Acceptance RevB  PM07-6636
     Jason Perks/s/ Jason Perks

Project ManagerDesigned Conveyer Systems4890 Kendrick, SEGrand Rapids, MI 49512Agreed and accepted this 7 day of June, 2007.Frank Buettner/s/ Frank Buettner

President & Chief Operating OfficerRedEnvelope, Inc149 New Montgomery StreetSan Francisco, CA 94105
 (DCS LOGO)
    
    Designed Conveyor Systems of Michigan, Inc.
4890 Kendrick St. SE
Grand Rapids, MI 49512
(616) 977-3950 phone(616) 977-5006 fax
Jason. Perks@dcsmich.com
    
    Page 2 of 2